New 225,000 Square Foot Facility

• Concept design
• Final design
• Master planning
• Construction management
• Project management
• Process engineering
• Packaging engineering
• Program Management

Multi-Purpose Vessel Conversion

Conversion of an existing Multi-Purpose Vessel (MPV) for use as a temporary sucrose storage and distribution vessel. Sucrose intended to replace HFCS were used in tea and beer.

Project Scope

• Design of alterations to tank and existing lines to accommodate new use
• Design and construction of three skids (unload, distribution, glycol heating)
• Process and utility tie-ins
• Temperature sensitive material, must be kept greater than 100º Fahrenheit

Ethanol Based Ingredients

Installation of over 500 feet of piping and equipment to allow for receiving a new 90% ethanol based ingredient (E1) that is to be used in a new product.

Project Scope

• Design of ingredient receiving and delivering to blend point
• Design of chilling product before carbonation
• Design and construction of process and utility piping
• Process and utility tie-ins
• Process Design, Layout, and P&ID development
• Equipment Procurement
• Managed a 10 day effort to install and commission the system. This included coordinating between the plant, mechanical contractor, electrical contractor, and programmers
• Relocated a heat exchanger that is being used in an existing process (had to jumper the product line)  and retro-fitted it to cool the root beer before carbonation
• Coordinated major process and utility tie-ins
• Executed water testing and CIP of new line, which required interfacing with an unrelated system to supply water, as there is no ready water supply at unload
• Successful readiness within 13 days of project inception
• System modifications 
• Equipment Procurement to replace “borrowed” equipment. Project was so fast track that chiller, micromotion, and various instrumentation were taken from other processes temporarily.
• Possible design for routing to Flash Pasteurizer prior to product release tank.
• Current design share blend and blended supply line with the C1 system. Future work includes a dedicated E1 blend and blended supply line, with a dedicated water line to blend.

Greenfield Wine Production Facility

Project Scope

• New 660,000 ft² Facility
  • 260,000 ft² Bottling Hall, 400,000 ft² Warehouse
• Three Bottling Lines
• Three Process Systems from Bottling Cellar to Fillers
  • Design Group Wine Process Skids
  • Integrated cellar, smart pumps, pigging

Design Group Scope of Work

• Project Management
• Facility Design (Civil, Structural, Architectural)
• Utility System Design
• Process System Design & Automation
• Packaging System Design & Automation
• Construction Management
• Start-up Support and Training

Approach

• Stage Gate
• Design – Bid (Owner-held contracts)

Material Receiving and Process Systems

Design and Installation of numerous material and ingredient receiving systems, including HFCS, Dry Additives, Granulated Sucrose, Frozen Juices and Concentrates

Process Utilities:
Design and Installation of Steam, Cooling, and Water systems in beverage plants

Sucrose Storage Tanks

Installation of two 20,000 gallon permanent sucrose storage tanks (heat traced and insulated), relocation of two Phase 1 skids, and a new skid for tank in/tank out (product and CIP) capabilities.

Project Scope

•   Design of new tanks to store sucrose
•   Design and construction of new routing skid
•   Process and utility tie-ins
•   Integration of new system

Cat Litter Line Expansion

Provided total integrated solution involving facility, process, packaging and controls engineering and construction management services for a new Cat Litter Line.  Project consisted of a new rail spur addition, rail unloading canopy, a bentonite unloading pit, structural towers for process conveyors, a limestone load-out building, all new interior platforms and supports for process equipment and tanks, as well as, packaging line supports. 

New Green Facility for Progressive Brewer

Design Group provided custom energy conservation measures in our design of the brewery utilities.

Design Group Scope of Work:

• Medium Temperature Hot Water (MTHW) versus Steam: Steam is used almost universally in the US brewing industry for process heating. Design Group provided innovative MTHW system providing higher efficiency and significantly lower operating cost than traditional steam systems.
• CO₂ Vaporization with Glycol: Bulk liquid CO₂ returned to gaseous state by using warm glycol return. Provides phase change for CO₂ and “free-cooling” of the process glycol.
• High Efficiency Ammonia Refrigeration System: Still the most efficient cooling system in this temperature range.
• Electrical Distribution, Compressed Air, and Water systems all designed with reliability and efficiency in mind.
• LEED BD+C certification is in progress for this brewery.

New 204,000 Square Foot Distribution Facility

Site real estate due diligence, facility planning, architecture, design and construction management for a new 204,000 ft² Sales Service Center.

Cake Mixing and Ingredient Upgrade

Whole and white egg handing and CIP systems

Project Scope

• Tote Unloading
• Temperature Control
• Metered Transfer to Blending
• CIP

Design Group Scope of Work

• Project Management
• Process Engineering
• Design
• Equipment Procurement
• System Integration
• Installation
• Startup Support

Sanitary and CIP Upgrade for Sauces

Sanitary audits and CIP upgrade for sauces

Project Scope:

• Sanitary audits
• CIP audits
• Process Improvements to pasteurizer, homogenizer, pipe routing and CIP sizing

Design Group Scope of Work:

• Project Management
• Process Engineering
• Design
• Equipment Procurement
• System Integration
• Installation 
• Startup Support